毕博-浦东软件园—介绍精益生产-英文版.pptVIP

An Introduction to Lean Manufacturing May 2003 OBJECTIVES OVERVIEW WHAT IS LEAN MANUFACTURING? LEAN PRODUCTION – BASIC DEFINITION THE CREATION OF LEAN—THE TOYOTA PRODUCTION SYSTEM “LEAN” OPERATIONS CREATE A COMPETITIVE ADVANTAGE OVERVIEW CORE LEAN OPERATIONS CONCEPTS* 8 KINDS OF WASTE ‘MUDA’ VISUAL MANAGEMENT 5S WORKPLACE ORGANIZATION EMPLOYEE INVOLVEMENT CORE LEAN OPERATIONS CONCEPTS* CONTINUOUS FLOW PROCESSING PULL SCHEDULING CORE LEAN OPERATIONS CONCEPTS* IMPACT OF SMALLER LOT SIZES STANDARDIZED WORK – TAKT TIME APPLICATIONS OF TAKT TIME—LINE BALANCE CORE LEAN OPERATIONS CONCEPTS* DELIVERING QUALITY THE FIRST TIME THROUGH ‘POKA YOKE’ STANDARDIZED WORK INSTRUCTIONS TOTAL PREVENTATIVE MAINTENANCE ‘TPM’ OVERVIEW LEAN SIMULATION – “CARD GAME” OVERVIEW LEAN SIMULATION – “CARD GAME” OVERALL SETUP ROUND 1 – BASELINE BATCH PROCESSING ROUND 2 – CONTINUOUS FLOW ROUND 3 – BALANCED STATIONS ROUND 4 – MULTIFUNCTIONAL WORKERS LEAN SIMULATION INSTRUCTIONS (ROUND 1) INSTRUCTION SHEET FOR SENIOR WRITER #1 LEAN SIMULATION INSTRUCTIONS (ROUND 1) INSTRUCTION SHEET FOR SENIOR WRITER #2 SIMPLIFIED INSTRUCTION SHEET FOR SENIOR WRITER #1 AND #2 –TO BE GIVEN BEFORE ROUND #4 LEAN SIMULATION INSTRUCTIONS (ROUND 1) LEAN SIMULATION INSTRUCTIONS (ROUND 1) LEAN SIMULATION INSTRUCTIONS (ROUND 1) LEAN SIMULATION INSTRUCTIONS (ROUND 1) OVERVIEW OEE CHARTS OVERALL EQUIPMENT EFFICIENCY—MEASURE EQUIPMENT PERFORMANCE LABOR PRODUCTIVITY: CHART MAINTENANCE—MEASURE PREPARATION VS REPAIR TIME LABOR VALUE-ADDED CHART—MEASURE VALUE ADDED VS NON-VALUE ADDED TIME FOR OPERATIONS REDUCING CHANGEOVER TIMES—THE SMED* APPROACH—MEASURE INDIVIDUAL ELEMENTS OF CHANGEOVER TIME ALCOA’S LEAN TRANSFORMATION PROCESS ALCOA’S LEAN TRANSFORMATION RESULTS LEAN OPERATIONS HAVE HELPED ALCOA BREAK OUT OF THE ALUMINUM PRICE CYCLE Standardizing current work practices assures quality through stable repeatable production processes Each production system leverages a suite of common tools and techniques to bui